Systems and methods for automatically loading and setting a rail fastener driving workhead unit

ABSTRACT

A rail fastener driving machine used for performing a spiking operation is provided, and includes a rail fastener workhead unit configured for driving a fastener into a rail tie. Also included in the machine is a position feedback system configured for controlling the spiking operation of the fastener driving machine based on a position signal and a mode signal, and a position sensor connected to the position feedback system for generating the position signal relative to a cylinder connected to the workhead unit, the position sensor transmitting the position signal to the position feedback system. The mode signal indicates an operation mode selected by an operator, and the workhead unit is actuated by the cylinder based on the mode signal for automatically positioning the workhead unit for driving the fastener into the rail tie.

CROSS-REFERENCE

This application claims priority under 35 USC 119(e) from U.S. Provisional Application Ser. No. 61/867,888 filed Aug. 20, 2013.

BACKGROUND

The present disclosure generally relates to railroad right-of-way maintenance machinery, and more particularly relates to machinery used for driving fasteners into rail ties for securing rail tie plates and rails to the ties.

Rail fasteners as contemplated herein include cut spikes, lag screws, hairpin spikes and other types of rail fasteners used for retaining tie plates upon ties, and rails upon tie plates, as are known to skilled practitioners. In some cases in the specification, “spikes” may be used interchangeably with “rail fasteners.” The use of the term “spikes” is not intended to limit the scope of the present invention.

Conventional railroad maintenance machine operations include spike driving, spike pulling, tie boring, tie replacement, lag screw application, anchor removing, and other related tasks. Each machine is designed for mechanically performing a specific task under operator control. Specifically, a rail fastener driving machine is provided to drive spikes into ties, also known as spiking. Such rail fastener driving machines typically include a frame which is either self-propelled or towable along a railroad track.

A fastener driving workhead unit actuated by a fluid power cylinder is provided with a reciprocating element for impacting a fastener and driving it into a tie. A fastener magazine is constructed and arranged for conveying the fasteners sequentially from the magazine to a selected location in operational relationship to the reciprocating element. When the workhead unit is fully retracted, an operator manually loads the spike into the workhead unit after visually verifying the workhead unit's current position. Repeated visual verifications are burdensome to the operator, and lengthen a timed cycle of each spiking operation. Thus, there is a need for developing an improved system and method of an automatic fastener loading operation.

SUMMARY

The present disclosure is directed to a rail fastener driving machine or a spiker having an automatic position feedback system. Specifically, the position feedback system improves a timed cycle of a fastener loading operation, and reduces a number of manual operator tasks during the operation. As a result, an improved, e.g., faster and more convenient, fastener loading operation is achieved without compromising the operational sequence of the fastener driving machine.

One aspect of the present machine is that, as described in further detail below, the position feedback system determines whether a workhead unit is in a fastener loading position, which refers to a position where the workhead unit has reached an upper limit of its operational range relative to a spiker cylinder that actuates the workhead unit. When the workhead unit is in the fastener loading position, a fastener magazine automatically loads a fastener into the workhead unit under the control of the position feedback system.

Another important aspect is that the present position feedback system operates the fastener driving machine automatically without manual operator intervention, and thus saves time during railroad maintenance. Consequently, the cycle time of the spiking operation is significantly reduced. More specifically, the present position feedback system automatically loads the spike into the workhead unit when the workhead unit is in the fastener loading position without having to verify the workhead unit's position. After the automatic loading, the workhead unit automatically transitions to a set position, which refers to a position where the spike is positioned above a tie plate hole within a predetermined distance between a lower tip of the spike and an opening of the tie plate hole, thereby being ready for spiking.

In one embodiment, a rail fastener driving machine used for performing a spiking operation is provided, and includes a rail fastener workhead unit configured for driving a fastener into a rail tie. Also included in the machine is a position feedback system configured for controlling the spiking operation of the fastener driving machine based on a position signal and a mode signal, and a position sensor connected to the position feedback system for generating the position signal relative to a cylinder connected to the workhead unit, the position sensor transmitting the position signal to the position feedback system. The mode signal indicates an operation mode selected by an operator, and the workhead unit is actuated by the cylinder based on the mode signal for automatically positioning the workhead unit for driving the fastener into the rail tie.

In another embodiment, a method for performing a spiking operation of a rail fastener driving machine is provided using a position feedback system, and includes controlling the spiking operation based on a position signal and a mode signal; generating the position signal relative to a cylinder connected to a workhead unit of the rail fastener driving machine; receiving the position signal from a position sensor connected to the position feedback system; transmitting the position signal to the position feedback system; generating the mode signal based on an operation mode selected by an operator; and actuating the workhead unit using the cylinder based on the mode signal for automatically positioning the workhead unit for driving a fastener into a rail tie.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary side perspective view of the present spike driving machine featuring a spike driving workhead unit in a set position;

FIG. 2 is a fragmentary side perspective view of the spike driving machine of FIG. 1 in a down or driving position;

FIG. 3 is an enlarged fragmentary side perspective view of the present jaw assembly in an open position;

FIG. 4 is an enlarged fragmentary side perspective view of the jaw assembly of FIG. 3 in a closed position;

FIG. 5 is a functional block diagram of the present position feedback system featuring functional modules; and

FIG. 6 illustrates an exemplary spike loading and setting method in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

Referring now to FIGS. 1-2, the present spike driving machine is generally designated 10 and is designed to drive a railroad spike or fastener 12 into a railroad tie 14 for securing a rail tie plate 16 and a rail 18 to the tie on a railroad track 20. Conventionally, the spike driving machine 10 is mounted upon a railway maintenance machine or base unit (not shown). Several types of spike driving machines are known, and exemplary models are described in commonly assigned U.S. Pat. Nos. 4,579,061; 4,777,885; 5,191,840; 5,671,679; and 7,104,200, all of which are incorporated by reference herein.

Included in the machine 10 is a main maintenance machine frame 22 supported on wheels (not shown) such that the frame is constructed and arranged for being movable along the railroad track 20. For driving the spike 12 into the tie 14, a spike driving workhead unit 24 is provided with a reciprocating hydraulic impact hammer (not shown), which is reciprocally vertically movable relative to the rail 18. A fluid power, preferably hydraulic, spiker cylinder 26 is provided for actuating and controlling vertical movement of the spike driving workhead unit 24 via a slider bracket 28 relative to the main railway maintenance machine frame 22, as taught in co-pending U.S. Patent Application No. 61/867,837 (Attorney Docket No. 1425.114553), incorporated by reference.

A lower end 30 of the workhead unit 24 is attached to a hammer bushing 32 having a substantially cylindrical shape for accommodating an extension coupler 34. The extension coupler 34 is releasably secured to the hammer bushing 32 by pivotally fastening a hammer bushing clamp 36. An anvil assembly, generally designated 38, includes the extension coupler 34 at its upper end. Further included in the anvil assembly 38 is a tube-like anvil sleeve 40 that defines a passageway for a shaft-like anvil 42 within the sleeve. During spiking, the anvil 42 travels reciprocally vertically inside the sleeve 40 to engage the head of the spike 12.

A jaw assembly, generally designated 44, includes a pair of spike gripping jaws 46 mounted to a jaw block 48 via a pair of rod eyes 50 to grasp the spike 12. In operation, the jaws 46 are pressurized toward a closed or gripping position by the rod eyes 50, which are hydraulically or mechanically biased, e.g., spring biased, as is well known in the art. When the spike 12 held by the jaws 46 is positioned for percussion, the sleeve 40 is lowered toward the tie plate 16 to slidingly separate the jaws 46, and holds the spike 12 inside the sleeve 40 such that the anvil 42 drives the spike into the tie 14 (FIG. 2).

Referring now to FIGS. 1-4, also included in the jaw block 48 is a pair of guide rods 52. Not only do the rods 52 guide a vertical movement of the anvil assembly 38, but also guide a downward movement of the jaw assembly 44 during spiking. As is known in the art, the guide rods 52 are slidingly engaged in corresponding bores of a workhead feeder frame of the type disclosed in U.S. Pat. No. 5,398,616, which is incorporated by reference.

A magazine or spike feed mechanism, generally designated 54, is provided for accommodating a plurality of the spikes 12 and feeding them sequentially for driving by the anvil assembly 38. Preferably, the feed mechanism 54 includes an inclined, elongated chute 56 made of a pair of parallel bars 58 which guide the spikes 12 toward a delivery point 60. In the preferred embodiment, the feed mechanism 54 is inclined so that the spikes 12 move toward the delivery point 60 by gravity. At the delivery point 60, the anvil 42 powered by a hydraulic cylinder (not shown) of the workhead unit 24 engages the top portion or head of the spike 12 to drive it into the tie 14.

Referring again to FIGS. 1-4, an exemplary spike loading operation is shown using the present spike driving machine 10. Initially, the present spike loading operation begins with the wokhead unit 24 being fully retracted with the jaws 46 in an open position, ready for receiving the spike 12 (FIG. 3). Next, the spike 12 is loaded into the delivery point 60 from the magazine 54, and the jaws 46 securely grip the spike in place for spiking (FIG. 4). Then, the workhead unit 24 is adjustably positioned relative to the frame 22 for proper alignment of the gripped spike 12 into a selected hole 62 in the tie plate 16, also known as a set position (FIG. 1). While the tie plate 16 typically has multiple such holes 62, only one is shown for illustration purposes. After the alignment of the spike 12, the sleeve 40 is lowered onto an upper surface 64 of the tie plate 16, and the spike is subsequently driven into the tie 14 by the anvil 42, also known as a down or driving position (FIG. 2).

An important feature of the present spike driving machine 10 is that the spike loading operation is controlled by a position feedback device or system, generally designated 66. In a preferred embodiment, the position feedback system 66 is a software installed computer device having programmable modules for various functions. As used herein, the term “module” may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), a programmable logic controller (PLC) and/or memory (shared, dedicated, or group) that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.

Although the children modules residing in their respective parent modules are shown, the broad teachings of the present system can be implemented in a variety of forms. Thus, while this disclosure includes particular examples and arrangements of the modules, the scope of the present device should not be so limited since other modifications will become apparent to the skilled practitioner.

Referring now to FIGS. 1, 3-5, it is preferred that the present position feedback system 66 includes a central control module (CCM) 68, a position sensor 70, and a database 72. Overall operation of the feedback system 66 is controlled by the CCM 68. Positional information of the spiker cylinder 26 is provided by the position sensor 70 located preferably on top of the cylinder 26. Preferably, the spiker cylinder 26 includes a reciprocating rod as is known in the art. All relevant information can be stored in the database 72 for retrieval by the CCM 68, e.g., as a data storage device and/or a machine readable data storage medium carrying computer programs.

Also included in the CCM 68 is an interface module 74, which provides an interface between the CCM 68, the position sensor 70, and the database 72. The interface module 74 also controls operation of, for example, actuators 76, such as the spiker cylinder 26, and other related system devices, services, and applications. The other devices, services, and applications may include, but are not limited to, one or more software or hardware components, as are known in the art. The interface module 74 also receives signals, which are communicated to the respective modules, such as the CCM 68 and its children modules.

Regarding the children modules, a mode selection module 78 is provided for selecting an operation mode under which the position feedback system 66 is operated, and generating a mode signal M based on the mode selection. For example, an operator may select an OFF mode to operate the position feedback system 66 manually without automation. Other options include an AUTO-LOAD mode and an optional AUTO-LOAD-SET mode. The AUTO-LOAD mode refers to an operation mode in which the position feedback system 66 is operated with an automatic spike loading sequence only. Similarly, the optional AUTO-LOAD-SET mode refers to an operation mode in which the position feedback system 66 is operated with both automatic spike loading and setting sequences. A detailed description of each mode is described below.

A position detection module 80 receives a position signal P from the position sensor 70 via the interface module 74, and determines whether the workhead unit 24 is in a fastener loading position based on the position signal P. As discussed above, the fastener loading position refers to a position where the workhead unit 24 is fully retracted and has reached an upper limit 82 of its operational range relative to the spiker cylinder 26. When the workhead unit 24 is in the fastener loading position, the jaws 46 are in the open position, thereby preparing to receive the spike 12 from the magazine 54 (FIG. 3).

A spike loading module 84 performs the automatic spike loading sequence by operating the fastener magazine 54 in response to the mode signal M. Specifically, when the workhead unit 24 is in the fastener loading position and the mode signal M indicates either the AUTO-LOAD mode or the optional AUTO-LOAD-SET mode, the spike loading module 84 automatically loads the spike 12 into the delivery point 60 such that the jaws 46 switch to the closed position and securely grip the spike 12 for spiking (FIG. 4).

Returning now to FIGS. 1-2 and 5, a spike setting module 86 performs the automatic spike setting sequence in response to the mode signal M. Similar to the spike loading module 84, when the mode signal M indicates the optional AUTO-LOAD-SET mode, the spike setting module 86 automatically transitions the workhead unit 24 to a set position. As discussed above, the set position refers to a position where the spike 12 is positioned above the tie plate hole 62 within a predetermined distance D between a lower tip 88 of the spike and an opening of the tie plate hole (FIG. 1). An exemplary distance D is approximately 0.25″.

After transitioning to the set position, a spiking module 90 actuates the workhead unit 24 to be in a down or driving position under the action of the spiker cylinder 26. The down or driving position refers to a position where the anvil sleeve 40 is lowered onto the tie plate 16 such that the anvil 42 inside the sleeve 40 drives the spike 12 into the tie 14 by percussion (FIG. 2). As a result, the tie plate 16 and the rail 18 are secured to the tie 14.

Referring now to FIG. 6, an exemplary method of the spike loading and setting sequences is shown using the present position feedback system 66. Although the following steps are primarily described with respect to the embodiments of FIGS. 1-5, it should be understood that the steps within the method may be modified and executed in a different order or sequence without altering the principles of the present disclosure.

The method begins at step 100. In step 102, as shown in FIG. 5, the mode selection module 78 generates a mode signal M based on an operation mode selection. For example, an operator can press one of the mode buttons disposed on a keypad of a hand controller or keyboard for selecting one of the operation modes. As for a complete manual mode, the operator presses an OFF mode button, or does not select any automatic mode. As for available automatic modes, the operator selectively triggers either an AUTO-LOAD mode button or an AUTO-LOAD-SET mode button. If a manual spike setting sequence is desired, the AUTO-LOAD mode button is selected, which performs only the automatic spike loading sequence. However, if a full automatic mode is desired, including both the automatic spike loading and setting sequences, the AUTO-LOAD-SET mode button is selected.

In step 104, the mode selection module 78 determines whether the position feedback system 66 is in one of the automatic modes, namely the AUTO-LOAD mode or the optional AUTO-LOAD-SET mode based on the mode signal M. If the selected mode is either one of the automatic modes, control proceeds to step 106. Otherwise, control proceeds to step 108.

In step 106, the position detection module 80 receives the position signal P from the position sensor 70 via the interface module 74. In step 108, the operator manually performs the spike loading sequence.

In step 110, the position detection module 80 determines whether the workhead unit 24 is in the fastener loading position based on the position signal P. If the workhead unit 24 is in the fastener loading position, then control proceeds to step 112, else control returns to step 106 to wait until the workhead unit 24 reaches the upper limit 82 of its operational range, as illustrated in FIG. 1.

In step 112, the spike loading module 84 receives the mode signal M from the mode selection module 78, and performs the automatic spike loading sequence in response to the mode signal M. In the preferred embodiment, this step is performed regardless of the automatic mode type as long as the position feedback system 66 is in one of the automatic modes.

In step 114, based on the mode signal M, if the position feedback system 66 is in the optional AUTO-LOAD-SET mode, then control proceeds to step 116. Otherwise, control proceeds to step 118. In step 116, the a spike setting module 86 receives the mode signal M from the spike loading module 84, and performs the automatic spike setting sequence in response to the mode signal M. It is contemplated that the automatic spike loading and setting sequences can be overridden by the operator and switched to the manual mode at any step if required.

In step 118, the operator manually performs the spike setting sequence. In step 120, the spiking module 90 actuates the workhead unit 24 to be in the down or driving position, and drives the spike 12 into the tie 14 by percussion. Control ends at step 122.

While a particular embodiment of the present spike driving machine has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the present disclosure in its broader aspects and as set forth in the following claims. 

What is claimed is:
 1. A rail fastener driving machine used for performing a spiking operation, comprising: a rail fastener workhead unit configured for driving a fastener into a rail tie; a position feedback system configured for controlling the spiking operation of the fastener driving machine based on a position signal and a mode signal; and a position sensor connected to the position feedback system for generating the position signal relative to a cylinder connected to the workhead unit, the position sensor transmitting the position signal to the position feedback system, wherein the mode signal indicates an operation mode selected by an operator, and the workhead unit is actuated by the cylinder based on the mode signal for automatically positioning the workhead unit for driving the fastener into the rail tie.
 2. The rail fastener driving machine of claim 1, further comprising a mode selection module configured for selecting the operation mode under which the position feedback system is operated, and generating the mode signal based on the mode selection.
 3. The rail fastener driving machine of claim 1, wherein the operation mode includes at least one of: an off mode for operating the position feedback system manually without automation; an auto-load mode for operating the position feedback system with an automatic fastener loading sequence; and an auto-load-set mode for operating the position feedback system with an automatic fastener loading and setting sequences.
 4. The rail fastener driving machine of claim 1, further comprising a position detection module configured for receiving the position signal from the position sensor for determining whether the workhead unit of the rail fastener driving machine is in a fastener loading position based on the position signal.
 5. The rail fastener driving machine of claim 4, wherein the fastener loading position refers to a position where the workhead unit is fully retracted and has reached an upper limit of its operational range relative to the cylinder, such that when the workhead unit is in the fastener loading position, fastener gripping jaws are in an open position, thereby preparing to receive the fastener from a fastener magazine.
 6. The rail fastener driving machine of claim 1, further comprising a spike loading module configured for performing an automatic fastener loading sequence by operating a fastener magazine in response to the mode signal.
 7. The rail fastener driving machine of claim 6, wherein when the workhead unit is in a fastener loading position and the mode signal indicates either an auto-load mode or an auto-load-set mode, the spike loading module automatically loads the fastener into a delivery point such that fastener gripping jaws switch to a closed position and securely grip the fastener for spiking.
 8. The rail fastener driving machine of claim 1, further comprising a spike setting module configured for performing an automatic fastener setting sequence in response to the mode signal.
 9. The rail fastener driving machine of claim 8, wherein when the mode signal indicates an auto-load-set mode, the spike setting module automatically transitions the workhead unit to a set position.
 10. The rail fastener driving machine of claim 9, wherein the set position refers to a position where the fastener is positioned above a tie plate hole within a predetermined distance between a lower tip of the fastener and an opening of the tie plate hole.
 11. The rail fastener driving machine of claim 1, further comprising a spiking module configured for actuating the workhead unit to be in a driving position under the action of the cylinder such that the fastener is driven into the rail tie using the workhead unit.
 12. A method for performing a spiking operation of a rail fastener driving machine using a position feedback system, comprising: controlling the spiking operation based on a position signal and a mode signal; generating the position signal relative to a cylinder connected to a workhead unit of the rail fastener driving machine; receiving the position signal from a position sensor connected to the position feedback system; transmitting the position signal to the position feedback system; generating the mode signal based on an operation mode selected by an operator; and actuating the workhead unit using the cylinder based on the mode signal for automatically positioning the workhead unit for driving a fastener into a rail tie.
 13. The method of claim 12, further comprising: selecting the operation mode under which the position feedback system is operated; and generating the mode signal based on the mode selection.
 14. The method of claim 12, wherein the operation mode includes at least one of: an off mode for operating the position feedback system manually without automation; an auto-load mode for operating the position feedback system with an automatic fastener loading sequence; and an auto-load-set mode for operating the position feedback system with an automatic fastener loading and setting sequences.
 15. The method of claim 12, further comprising: determining whether the position feedback system is in one of an auto-load mode or an auto-load-set mode based on the mode signal; receiving the position signal from the position sensor when the operation mode is in either one of the auto-load or auto-load-set mode.
 16. The method of claim 12, further comprising: performing an automatic fastener loading sequence in response to the mode signal when the operation mode is in either one of an auto-load or auto-load-set mode; and manually performing the fastener loading sequence when the operation mode is in neither one of the auto-load or auto-load-set mode.
 17. The method of claim 12, further comprising: performing an automatic fastener setting sequence in response to the mode signal when the operation mode is in an auto-load-set mode; and manually performing the fastener setting sequence when the operation mode is not in the auto-load-set mode.
 18. The method of claim 12, further comprising overriding an automatic fastener loading sequence or an automatic fastener setting sequence by the operator.
 19. The method of claim 12, further comprising automatically transitioning the workhead unit to a set position when the mode signal indicates an auto-load-set mode.
 20. The method of claim 12, further comprising actuating the workhead unit to be in a driving position under the action of the cylinder such that the fastener is driven into the rail tie using the workhead unit. 